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Discussion Starter #1 (Edited)
I was too impatient to wait for any aftermarket light bar for the bumper area of the Gen 1 so I decided to build one myself. This write-up is picture heavy to help everyone see what I did so that you can get ideas to build this even better. Here it is....

I started out with an idea of mounting some angled metal to the crossbar behind the gray plastic cover of the front bumper. Below you will see my mock-up drawings for the bar and the materials list attached. After that you will see how I wired it up and then a cross-section view of the mounting setup. These first five images are for reference to get you started. All of the following images illustrate my progress through the install.

Light Bar Drawings and Material/Tools List





Wiring Diagram and Materials/Tools List





Crosscut View



I chose a piece of angled aluminum to construct the bar from and decided to install a pair of Hella FF75 Driving Lights and a pair of Hello FF75 Fog Lights (I used the kits along with some additional materials). I cut the metal before taking a picture so I do not have a picture of it in raw form.



Used the drawings above to get the measurements I used on the aluminum to get the right shape. After measuring carefully, cut it and mark the holes to be used for mounting the lights.



After drilling the holes I mocked-up the mounts to make sure they were good to go.







Then I painted the outward facing sides of the bar so that it would blend in with the truck. I used Rust-o-leum Glossy Black and primer.







Once the light bar was cut, drilled and painted, it was time to get it mounted. Remove the gray plastic piece in the bumper to give yourself room to work.

I wanted to leave room to tuck the gray plastic piece underneath the light bar so I left space for it by using cardboard as a spacer as seen below.



At this point I drilled the three holes that I used to mount the light bar to the crossbar. I drilled the first one on center and then measured 7 inches to the left and right and drilled the other holes there. Once they were done, I had a buddy hold the light bar where I wanted it and drilled through the crossbar holes again which made the marks I needed on the light bar. Once marked by the drill, I went and drilled the holes in the light bar. I then attached the light bar to the crossbar with the three bolts as seen below and also test fit the lights.






Now to the wiring. Please see my wiring diagram above for a more detailed view of what I did. My Xterra already had a hole in the firewall where the wiring for an amp was installed by the first owner. The hole was large enough to get six 18ga wires through it. Four of them were used for the switches and the other two will be used for future modifications. Another write-up maybe? You can see where the hole is below.



With the glove box removed, you can see where the wiring came into the front passenger floorboard.



And where I pull them over to the drivers floorboard...



These wires were connected to the battery, switches, and relays. Once I knew I could get wiring to the cabin, I started wiring the lights. I ran separate 12 gauge wires to each light and grounded the lights locally to the light bar. See below for more pics.







The middle mounting bolt was 1/2" longer than the other on purpose so I could use it as a common grounding point.



Once the lights were wired and mounted, I covered the wires with wire loom.



I brought the wiring up from the bumper, in through the passenger headlight area and into the engine compartment.



I followed my diagram and started working on the connections. Here is a picture of some of the wiring and the 15 amp fuses I used on each set.



Here is a pic when it was almost done. I mounted the relays on the left back side of the engine compartment.



Once I was done in the engine compartment I cleaned up the wiring inside the cabin.



The switches from Oly4x4.com do not fit the dash holes unless you remove the notch in the upper-left corner of the holes. I used a small hacksaw blade to get them out as I don't have a Dremel (which I really want now).



[IMAGE LIMITATION: See next post]
 

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Discussion Starter #2 (Edited)
...continued.

I added additional wiring for the switch grounds and terminated them on the metal near the shifters.



I wired up the switches and installed them in the dash.





All done. Here are a few pictures of the final product...







And with the gray cover re-installed.



Now go out and do this or something cooler and post your pictures! :D

Chuck
 

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Well done! I really like the look of lights in that spot on the Xterra, and I had started gathering materials to do this when I decided I'd rather have a hidden winch mount. Budget's really tight right now, so no mods anytime soon for me. But one day. Again, I really dig your lights. Good work!
 

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Nice job! Very clean looking.
 

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Kick ass!! thats awesome dude

Yea those OLY4x4 switches are sweet, i used one for my lights
 

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Discussion Starter #7
Thanks y'all. It turned out just as I had imagined so I'm real happy about it.
 

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Looks great!!! Really good write up too...
 

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I would be very weary of that wiring through that bulkhead dude!
 

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I would be very weary of that wiring through that bulkhead dude!
That was exactly what I was thinking, lol.

Nice write up and cool install, but you really want to go back and put a grommet around those wires where they come through the firewall. (They need to be going through rubber or plastic and never touching metal). Other than that, Cool.
 

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Yeah - I'd add a split grommet to protect the wires from abrasion too.

I'd also reverse the fog and driving lights, as the fogs should be on the outside, not the center, for best performance.

It looks great though, and you did an amazing job on the write up....very nice.

:D
 

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Yes, excellent write up!
 

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Discussion Starter #14
Thanks for the comments. I was planning to pick up a grommet or something like that this weekend to protect the wiring just as you guys have suggested. I'll post an updated pic after I fix that. About the positioning, I wasn't really sure. I was thinking the driving lights could be closer to the bumper as the beam is tight and it wouldn't be affected as bad as the fogs if they were too close (as in blocking the periphery). I can always move them, it wouldn't take long.
 

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At night your truck looks like its smiling.:mocking:

Nice job, I am working on my roof mounted fog lights little by little. Still wondering how the hell I can safely and snuggly fit the wiring through the roofing down into the pillar. Used to stealth mod pc cases so wires showing = a no no.
 

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Discussion Starter #16
haha :)

Others have drilled right through the roof. I think it would be hard to take a drill to my roof but if its sealed right it would be ok. Good luck and show pics if you do it.

Chuck
 

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that looks sick bro I'm thinkin of doing it thnx...oh ? i see guys with the second battery do y'all connect it to the original or just on its own?
 
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